Pump Wisdom Problem Solving for Operators anaSpecialîsts By Heinz P. Blocn

Pump Wisdom Problem Solving for Operators anaSpecialîsts

By Heinz P. Blocn

Table of Contents

1. Principles of Centrifugal Process Pumps

2. Pump Selection and Industry Standards

3. Foundations and Base Plates

4. Piping, Stationary Seals, and Gasketing

5. Rolling Element Bearings

6. Lubricant Application and Cooling Considerations

7. Lubricant Types and Key Properties

8. Bearing Housing Protection and Cost Justification

9. Mechanical Sealing Options for Long Life

10. Pump Operation

11. Impeller Modifications and Pump Maintenance

12. Lubrication Management

13. Pump Condition Monitoring: Pump Vibration,Rotor Balance, and Effect on Bearing Lif

14. Drivers, Couplings, and Alignment

15. Fits, Dimensions, and Related Misunderstandings Failure Statistics and Structured Failure Analysis

Preface
Pump users have access to hundreds of books and many thousands of articles dealing with pump subjects. So, one might ask, why do we need this text? I believe we need it because an unacceptably large number of process pumps fail catastrophically every year. An estimated 95% of these are repeat

failures, and most of them are costly, dangerous, or both. I wanted to explain some elusive failure causes and clearly map out permanent remedial action.My intent was to steer clear of the usual consultant-conceived generalities and give you tangible, factual, and well-defined information throughout.As any close review of what has been offered in the past will uncover,many texts were written primarily to benefit one particular job function,ranging from pump operators to pump designers. Some books contain ahidden bias, or they appeal to a very narrow spectrum of readers; others are perhaps influenced by a particular pump manufacturer's agenda. Give this text a chance; you'll see that it is different. I gave it the title Pump Wisdom because wisdom is defined as applied knowledge. If you concur with this very meaningful definition you will be ready for a serious challenge. That challenge is to practice wisdom by acting on the knowledge this text conveys.Although I had written or co-authored other books and dozens of articles on pump reliability improvement, some important material is too widely dispersed to be readily accessible. Moreover, some important material has never been published before. I therefore set out to assemble, rework, condense, and explain the most valuable points in a text aimed at wide distribution. It was to become a text with, I hope, permanence and "staying power."To thus satisfy the scope and intent of this book, I endeavored to keep theoretical explanations to a reasonable minimum and to limit the narrative to 200 pages. Putting it another way, I wanted to squeeze into these 200 pages material and topics that will greatly enhance both pump safety and reliability.All that is needed is the reader's solid determination to pay close attention and to follow up diligently.Please realize that in years past, many pump manufacturers have primarily concentrated their design and improvement focus on the hydraulic end. Indeed, over time and in the decades since 1960, much advancement has been made in the metallurgical and power-efficiency-related performance of the hydraulic assembly. All the while, the mechanical assembly or drive end of process pumps was being treated with relative indifference. In essence,there was an imbalance between the attention given to pump hydraulics and pump mechanical issues.Recognizing indifference as costly, this text tries to rectify some of these imbalances. My narrative and illustrations are intended to do justice to both the hydraulic assembly and the mechanical assembly of process pumps. That said, the book briefly lays out how pumps function and quickly moves to guidelines and details that must be considered by reliablity-focused readers.A number of risky omissions or shortcuts by pump designers, manufacturers,and users also are described.I also want the reader to know that the real spark for this book came from AESSEAL, a worldwide manufacturer of sealing products. I have come to appreciate them as an entity guided by quality principles, with a workforce that pursues excellence at every level of the organization. Of the many business entities I have worked with over the past five decades, they represent the one closest to my own ideal. They practice what a reliability-focused company should be doing; I consider diem an example of how a business should conduct itself. I also want to acknowledge them for rapidly providing artwork assistance whenever I asked.Please take from me a good measure of encouragement: Make good use of this book. Read it and apply it. Today, and hopefully years from now,remember to consult this material. Doing so will acquaint you with pump failure avoidance and the more elusive aspects of preserving pump-related assets. And so, although you undoubtedly have more problems than you deserve, please keep in mind that you also deserve access to more solutions than you previously knew about or currently apply. Sound solutions are available,and they are here, right at your fingertips. Use them wisely; they will be cost effective. The solutions you can discern from this text will have a positive effect on pump safety performance and asset preservation. They have worked at best-of-class companies and cannot possibly disappoint you.

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